Fluid Power with Applications

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Places emphasis on understanding how fluid power systems operate and on their practical applications. A basic background in the field of fluid power is provided, allowing students to understand the design, analysis, operation, and maintenance of fluid power systems.

Introduction to Fluid Power

1

(20)

Learning Objectives

1

(1)

What Is Fluid Power?

1

(2)

History of Fluid Power

3

(3)

Advantages of Fluid Power

6

(4)

Applications of Fluid Power

10

(4)

Components of a Fluid Power System

14

(3)

The Fluid Power Industry

17

(4)

Exercises

18

(3)

Physical Properties of Hydraulic Fluids

21

(36)

Learning Objectives

21

(1)

Introduction

21

(2)

Fluids: Liquids and Gases

23

(2)

Specific Weight, Density, and Specific Gravity

25

(5)

Force, Pressure, and Head

30

(7)

The SI Metric System

37

(3)

Bulk Modulus

40

(1)

Viscosity

41

(7)

Viscosity Index

48

(3)

Illustrative Examples Using the SI Metric System

51

(1)

Key Equations

52

(5)

Exercises

53

(4)

Energy and Power in Hydraulic Systems

57

(54)

Learning Objectives

57

(1)

Introduction

57

(2)

Review of Mechanics

59

(6)

Multiplication of Force (Pascal's Law)

65

(4)

Applications of Pascal's Law

69

(7)

Conservation of Energy

76

(1)

The Continuity Equation

77

(2)

Hydraulic Power

79

(5)

Bernoulli's Equation

84

(7)

Torricelli's Theorem

91

(2)

The Siphon

93

(1)

Energy, Power, and Flow Rate in the SI Metric System

94

(2)

Illustrative Examples Using the SI Metric System

96

(3)

Key Equations

99

(12)

Exercises

102

(9)

Frictional Losses in Hydraulic Pipelines

111

(30)

Learning Objectives

111

(1)

Introduction

111

(2)

Laminar and Turbulent Flow

113

(1)

Reynolds Number

114

(3)

Darcy's Equation

117

(1)

Frictional Losses in Laminar Flow

117

(1)

Frictional Losses in Turbulent Flow

118

(4)

Losses in Valves and Fittings

122

(5)

Equivalent-Length Technique

127

(1)

Hydraulic Circuit Analysis

128

(3)

Circuit Analysis Using the SI Metric System

131

(3)

Key Equations

134

(7)

Exercises

135

(6)

Hydraulic Pumps

141

(54)

Learning Objectives

141

(1)

Introduction

142

(2)

Pumping Theory

144

(1)

Pump Classification

145

(3)

Gear Pumps

148

(8)

Vane Pumps

156

(6)

Piston Pumps

162

(9)

Pump Performance

171

(7)

Pump Noise

178

(6)

Pump Selection

184

(1)

Pump Performance Ratings in Metric Units

185

(3)

Key Equations

188

(7)

Exercises

190

(5)

Hydraulic Cylinders and Cushioning Devices

195

(32)

Learning Objectives

195

(1)

Introduction

195

(2)

Hydraulic Cylinder Operating Features

197

(2)

Cylinder Mountings and Mechanical Linkages

199

(2)

Cylinder Force, Velocity, and Power

201

(3)

Cylinder Loads Due to Moving of Weights

204

(3)

Special Cylinder Designs

207

(1)

Cylinder Loadings through Mechanical Linkages

207

(6)

Hydraulic Cylinder Cushions

213

(3)

Hydraulic Shock Absorbers

216

(4)

Key Equations

220

(7)

Exercises

222

(5)

Hydraulic Motors

227

(33)

Learning Objectives

227

(1)

Introduction

227

(3)

Limited Rotation Hydraulic Motors

230

(2)

Gear Motors

232

(3)

Vane Motors

235

(3)

Piston Motors

238

(2)

Hydraulic Motor Theoretical Torque, Power, and Flow-Rate

240

(4)

Hydraulic Motor Performance

244

(4)

Hydrostatic Transmissions

248

(3)

Hydraulic Motor Performance in Metric Units

251

(2)

Key Equations

253

(7)

Exercises

255

(5)

Hydraulic Valves

260

(48)

Learning Objectives

260

(1)

Introduction

261

(1)

Directional Control Valves

262

(13)

Pressure Control Valves

275

(9)

Flow Control Valves

284

(8)

Servo Valves

292

(3)

Proportional Control Valves

295

(1)

Cartridge Valves

296

(7)

Hydraulic Fuses

303

(1)

Key Equations

304

(4)

Exercises

304

(4)

Hydraulic Circuit Design and Analysis

308

(41)

Learning Objectives

308

(1)

Introduction

308

(1)

Control of a Single-Acting Hydraulic Cylinder

309

(1)

Control of a Double-Acting Hydraulic Cylinder

310

(2)

Regenerative Cylinder Circuit

312

(4)

Pump-Unloading Circuit

316

(1)

Double-Pump Hydraulic System

317

(3)

Counterbalance Valve Application

320

(1)

Hydraulic Cylinder Sequencing Circuits

321

(1)

Automatic Cylinder Reciprocating System

322

(1)

Locked Cylinder Using Pilot Check Valves

322

(1)

Cylinder Synchronizing Circuits

323

(2)

Fail-Safe Circuits

325

(3)

Speed Control of a Hydraulic Cylinder

328

(4)

Speed Control of a Hydraulic Motor

332

(1)

Hydraulic Motor Braking System

332

(1)

Hydrostatic Transmission System

333

(2)

Air-Over-Oil Circuit

335

(1)

Analysis of Hydraulic System with Frictional Losses Considered

335

(4)

Mechanical-Hydraulic Servo System

339

(1)

Key Equations

340

(9)

Exercises

340

(9)

Hydraulic Conductors and Fittings

349

(28)

Learning Objectives

349

(1)

Introduction

349

(1)

Conductor Sizing for Flow Rate Requirements

350

(2)

Pressure Rating of Conductors

352

(4)

Steel Pipes

356

(4)

Steel Tubing

360

(5)

Plastic Tubing

365

(1)

Flexible Hoses

365

(6)

Quick Disconnect Couplings

371

(1)

Metric Steel Tubing

371

(3)

Key Equations

374

(3)

Exercises

374

(3)

Ancillary Hydraulic Devices

377

(43)

Learning Objectives

377

(1)

Introduction

377

(1)

Reservoirs

378

(3)

Accumulators

381

(11)

Pressure Intensifiers

392

(3)

Sealing Devices

395

(11)

Heat Exchangers

406

(4)

Pressure Gages

410

(2)

FlowMeters

412

(4)

Key Equations

416

(4)

Exercises

416

(4)

Maintenance of Hydraulic Systems

420

(30)

Learning Objectives

420

(1)

Introduction

421

(2)

Oxidation and Corrosion of Hydraulic Fluids

423

(1)

Fire-Resistant Fluids

424

(2)

Foam-Resistant Fluids

426

(1)

Fluid Lubricating Ability

426

(1)

Fluid Neutralization Number

427

(1)

Petroleum-Base Versus Fire-Resistant Fluids

427

(1)

Maintaining and Disposing of Fluids

428

(1)

Filters and Strainers

429

(5)

Beta Ratio of Filters

434

(2)

Fluid Cleanliness Levels

436

(2)

Wear of Moving Parts Due to Solid-Particle Contamination of the Fluid

438

(1)

Problems Caused by Gases in Hydraulic Fluids

439

(3)

Troubleshooting Hydraulic Systems

442

(4)

Safety Considerations

446

(1)

Environmental Issues

446

(1)

Key Equations

447

(3)

Exercises

448

(2)

Pneumatics: Air Preparation and Components

450

(54)

Learning Objectives

450

(1)

Introduction

451

(1)

Properties of Air

452

(2)

The Perfect Gas Laws

454

(6)

Compressors

460

(9)

Fluid Conditioners

469

(8)

Analysis of Moisture Removal from Air

477

(3)

Air Flow Rate Control with Orifices

480

(2)

Air Control Valves

482

(8)

Pneumatic Actuators

490

(8)

Key Equations

498

(6)

Exercises

499

(5)

Pneumatics: Circuits and Applications

504

(31)

Learning Objectives

504

(1)

Introduction

504

(3)

Pneumatic Circuit Design Considerations

507

(1)

Air Pressure Losses in Pipelines

508

(2)

Economic Cost of Energy Losses in Pneumatic Systems

510

(2)

Basic Pneumatic Circuits

512

(6)

Pneumatic Vacuum Systems

518

(4)

Sizing of Gas-Loaded Accumulators

522

(3)

Pneumatic Circuit Analysis Using Metric Units

525

(3)

Key Equations

528

(7)

Exercises

528

(7)

Basic Electrical Controls for Fluid Power Circuits

535

(20)

Learning Objectives

535

(1)

Introduction

535

(4)

Electrical Components

539

(3)

Control of a Cylinder Using a Single Limit Switch

542

(1)

Reciprocation of a Cylinder Using Pressure or Limit Switches

543

(1)

Dual-Cylinder Sequence Circuits

544

(1)

Box-Sorting System

545

(3)

Electrical Control of Regenerative Circuit

548

(1)

Counting, Timing, and Reciprocation of Hydraulic Cylinder

549

(6)

Exercises

551

(4)

Fluid Logic Control Systems

555

(25)

Learning Objectives

555

(1)

Introduction

555

(2)

Moving-Part Logic (MPL) Control Systems

557

(4)

MPL Control of Fluid Power Circuits

561

(4)

Introduction to Boolean Algebra

565

(6)

Illustrative Examples Using Boolean Algebra

571

(5)

Key Equations

576

(4)

Exercises

576

(4)

Advanced Electrical Controls for Fluid Power Systems

580

(67)

Learning Objectives

580

(1)

Introduction

580

(5)

Components of an Electrohydraulic Servo System

585

(3)

Analysis of Electrohydraulic Servo Systems

588

(8)

Programmable Logic Controllers (PLCs)

596

(10)

Key Equations

606

(5)

Exercises

607

(4)

APPENDIXES

A Sizes of Steel Pipe (English Units)

611

(2)

B Sizes of Steel Pipe (Metric Units)

613

(2)

C Sizes of Steel Tubing (English Units)

615

(2)

D Sizes of Steel Tubing (Metric Units)

617

(1)

E Unit Conversion Factors

618

(2)

F Nomenclature

620

(3)

G Fluid Power Symbols

623

(3)

H Answers to Selected Odd-Numbered Exercises

626

(5)

I Derivation of Key Equations

631

(5)

J Computer Analysis of Fluid Power Systems

636

(8)

K Exercises for Computer Solutions

644

(3)

Index

647

INTRODUCTION The primary purpose of the sixth edition ofFluid Power with Applicationsremains the same as that of the previous editions: to provide the student with in-depth explanation of the vast field of fluid power. As such, this book covers all subjects essential to understanding the design, analysis, operation, maintenance, and application of fluid power systems. It is written for associate and bachelor's degree candidates studying technology at community colleges, technical colleges, and four-year colleges and universities. In keeping with the previous editions, theory is presented where necessary, but the emphasis is on understanding how fluid power systems operate and on practical applications. The student then learns not only the "why" but also the "how" of fluid power systems operation. NEW IN THE SIXTH EDITION Based on input from users of the fifth edition and from my colleagues, the following changes have been incorporated into this book. Material on ancillary hydraulic devices (such as reservoirs, accumulators, pressure intensifiers, seals, heat exchangers, pressure gauges, and flowmeters) has been removed from various chapters and combined into a new Chapter 11. As a result the chapters dealing with major components, such as pumps, cylinders, motors, and valves, are more coherent and focused, resulting in enhanced read ability and understanding. Many of the example problems and end-of-chapter exercises have been changed to better reflect current industrial applications. The example problems and exercises encompass a wide range of subject matter and levels of difficulty to allow students to progress in an orderly manner. Section 8.6 has been added to include coverage on proportional control valves.. It has become increasingly more important to discuss the operation and application of these solenoid-operated valves because they provide precise, dependable, variable speed control of cylinders and motors in open-loop fluid power systems. A number of photographs and illustrations have been updated to reflect current fluid power technology. These include programmable logic controllers, microprocessors, and electrohydraulic servo systems. Section 12.11, on fluid cleanliness levels, has been added. The basis for controlling particle contamination of hydraulic fluid is to measure they fluid's cleanliness level. It is important to present this subject, because manufacturers of hydraulic equipment specify the fluid cleanliness levels required for providing the; expected life of their components. Derivations of key equations have been removed from various chapters and combined into a new Appendix I. This change allows students to better concentrate on applications without undue emphasis on mathematical analysis. This is especially valuable in early chapters where understanding the operation off fluid power components can be more difficult because of the simultaneous inclusion of mathematical theory. Appendix I should be used by instructors who want to pay more attention to teaching students how equations are derived.. A new Section 13.6 includes material on the analysis of moisture removal from air. Moisture in the air delivered by a compressor washes away lubricants, causing excessive wear in components such as cylinders, valves, and motors that contain moving parts. Moisture also causes metallic surfaces to rust, thus damaging plumbing components such as conductors and fittings. It is therefore; important to know how to determine and reduce the rate at which moisture enters a pneumatic system. Material on hydraulic cylinders and hydraulic motors (previously covered in a single chapter) has been rewritten and placed into two separate chapters for better clarity and focus. Chapter 6 is devoted to hydraulic cylinders, and Chapter7 concentrates on hydraulic motors. This change allows readers to obtain a better understanding